Battery cell connector

ABSTRACT

A battery cell connector includes a plurality of segments. The plurality of segments includes: a first terminal segment with first connecting elements for a battery pole of a first battery cell; a second terminal segment with second connecting elements for a battery pole of a second battery cell; and one or more additional segments connecting the first terminal segment to the second terminal segment. Each additional segment defines a plane and has a longitudinal axis. The battery cell connector further includes a plurality of bends coupling the plurality of segments together into a 3-D object. Each bend is located between a unique pair of adjacent segments of the plurality of segments. The pair of adjacent segments defines two distinct respective planes. The first terminal segment is not parallel to the second terminal segment. The first connecting elements are electrically coupled with the second connecting elements.

RELATED APPLICATIONS

This application claims priority to Chinese Patent No. 201510233602.6,entitled “POWER BATTERY CELL CONNECTOR, POWER BATTERY MODULES, POWERBATTERY PACKAGES, AND CAR,” filed on May 8, 2015, and Chinese Patent No.201510234575.4, entitled “POWER BATTERY CELL CONNECTOR, POWER BATTERYMODULES, POWER BATTERY PACKAGES, AND CAR,” filed on May 8, 2015, both ofwhich are incorporated by reference in their entirety.

This application is also related to U.S. application Ser. No.14/871,712, entitled “BATTERY CELL CONNECTOR,” filed Sep. 30, 2015, andU.S. application Ser. No. 14/871,739, entitled “BATTERY CELL CONNECTOR,”filed Sep. 30, 2015, both of which are incorporated by reference intheir entirety.

TECHNICAL FIELD

The disclosed embodiments relate generally to apparatuses for connectingbattery cells, and more particularly to apparatuses that electricallycouple battery cells while providing mechanical rigidity and/orvibration dampening.

BACKGROUND

Batteries have become a commonplace form of energy storage (e.g., foruse in hybrid and electric vehicles). Often, one or more battery cells(e.g., modules) are connected (e.g., in series or parallel) to increasethe storage capacity and/or power output of the battery system. Toconnect two battery cells in series, an anode of a first battery istypically connected with a cable to the cathode of a second battery.

A problem with battery cell connections arises when batteries are used,for example, in vehicles, because battery cables offer little if anymechanical support. For example, tolerances between the shape and sizeof the battery cells, along with vibrations experienced by the batterysystem from operating in a vehicle (e.g., vibrations between batterycells), can lead to mechanical and/or electrical failure of the batterysystem.

SUMMARY

Thus, there is need for battery cell connectors that provide mechanicalrigidity, support and/or vibration damping. To that end, disclosed arebattery module connectors that provide mechanical support and/orvibration damping when connecting battery cells.

In accordance with some embodiments, a battery cell connector includes aplurality of segments. Each segment defines a respective plane and has arespective longitudinal axis. The battery cell connector furtherincludes a plurality of bends coupling the plurality of segmentstogether into a 3-D object, each bend located between a unique pair ofadjacent segments of the plurality of segments, where the unique pair ofadjacent segments define two distinct respective planes. A first segmentof the plurality of segments includes one or more first connectingelements for a battery pole of a first battery cell and a second segmentof the plurality of segments includes one or more second connectingelements for a battery pole of a second battery cell. The one or morefirst connecting elements are electrically coupled with the one or moresecond connecting elements.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a perspective view of a first battery cell connector,in accordance with some embodiments.

FIG. 2 illustrates a partially-exploded-view of a first battery systemutilizing the first battery cell connector, in accordance with someembodiments.

FIG. 3 illustrates an assembly view of the first battery systemutilizing the first battery cell connector, in accordance with someembodiments.

FIG. 4 illustrates a close-up of a portion of the assembly view of thefirst battery system utilizing the first battery cell connector, inaccordance with some embodiments.

FIG. 5 illustrates a perspective view of a second battery cellconnector, in accordance with some embodiments.

FIG. 6 illustrates a top view of the second battery cell connector, inaccordance with some embodiments.

FIG. 7 illustrates a partially-exploded-view of a second battery systemutilizing the second battery cell connector, in accordance with someembodiments.

FIG. 8 illustrates a close-up of a portion of an assembly view of thesecond battery system utilizing the second battery cell connector, inaccordance with some embodiments.

FIG. 9 illustrates a partially-exploded-view of a third battery systemutilizing a third battery cell connector, in accordance with someembodiments.

FIG. 10 illustrates another partially-exploded-view of the third batterysystem utilizing the third battery cell connector, in accordance withsome embodiments.

FIG. 11 illustrates an assembly view of the third battery systemutilizing the third battery cell connector, in accordance with someembodiments.

FIG. 12 illustrates a close-up of a portion of the assembly view of thethird battery system utilizing the third battery cell connector, inaccordance with some embodiments.

FIG. 13 illustrates a perspective view of a fourth battery cellconnector, in accordance with some embodiments.

FIG. 14 illustrates a partially-exploded-view of a fourth battery systemutilizing the fourth battery cell connector, in accordance with someembodiments.

FIG. 15 illustrates another partially-exploded-view of the fourthbattery system utilizing the fourth battery cell connector, inaccordance with some embodiments.

FIG. 16 illustrates an assembly view of the fourth battery systemutilizing the fourth battery cell connector, in accordance with someembodiments.

FIG. 17 illustrates a close-up of a portion of the assembly view of thefourth battery system utilizing the fourth battery cell connector, inaccordance with some embodiments.

FIG. 18 illustrates a perspective view of a fifth battery cellconnector, in accordance with some embodiments.

FIG. 19 illustrates a partially-exploded-view of a fifth battery systemutilizing the fifth battery cell connector, in accordance with someembodiments.

FIG. 20 illustrates an assembly view of the fifth battery systemutilizing the fifth battery cell connector, in accordance with someembodiments.

FIG. 21 illustrates a close-up of a portion of the assembly view of thefifth battery system utilizing the fifth battery cell connector, inaccordance with some embodiments.

FIG. 22A illustrates a perspective view of an additional battery cellconnector, in accordance with some embodiments.

FIG. 22B illustrates another perspective view of the battery cellconnector shown in FIG. 22A, in accordance with some embodiments.

FIG. 23 illustrates a perspective view of another battery cellconnector, in accordance with some embodiments.

FIG. 24 illustrates a perspective view of another battery cellconnector, in accordance with some embodiments.

FIG. 25 illustrates a perspective view of another battery cellconnector, in accordance with some embodiments.

FIGS. 26A-26C illustrate a sheet metal process in accordance with someembodiments.

Like reference numerals refer to corresponding parts throughout thedrawings.

DESCRIPTION OF EMBODIMENTS

The battery cell connectors described herein include a sheet of material(e.g., metal) with bends and turns configured in such a way as toprovide mechanical rigidity and vibration dampening in one or moredirections, thus providing mechanical support to the interconnectsbetween battery cell terminals. For example, in some embodiments, thebattery cell connectors described herein include segments ofsubstantially flat sheets of metal that efficiently carry bending andshear loads along a longitudinal direction of each segment. The segmentsare coupled by bends (e.g., connections between two segments havingnon-planar longitudinal axes) and/or turns (e.g., connections betweentwo segments having non-parallel, but planar, longitudinal axis). Bycoupling segments by bends and turns, the battery cell connectorsdescribed herein are configured into a three-dimensional (3-D) objectthat provides mechanical compressional/shearing rigidity (e.g.,efficient carrying of bending and/or shear stress) in more than onedirection (e.g., two or three perpendicular directions) as well asrotational rigidity along more than one rotational axis (e.g., two orthree rotational axes). In addition, in some embodiments, the bendscoupling segments act a stiff springs that provide vibration dampingalong one or more rotational axes. As described below, FIGS. 1-21illustrate exemplary embodiments which are configured to provide rigidsupport and vibration dampening while fitting conveniently to existingbattery module geometries (e.g., the embodiments described belowdescribe example geometries for battery cell connectors).

Reference will now be made in detail to various implementations,examples of which are illustrated in the accompanying drawings. In thefollowing detailed description, numerous specific details are set forthin order to provide a thorough understanding of the present disclosureand the described implementations herein. However, implementationsdescribed herein may be practiced without these specific details. Inother instances, well-known methods, procedures, components, andmechanical apparatus have not been described in detail so as not tounnecessarily obscure aspects of the implementations.

FIG. 1 illustrates a perspective view of a first battery cell connector100 (e.g., also called a bus bar or a battery module connector), inaccordance with some embodiments. First battery cell connector 100includes a plurality of segments 102 (e.g., segments 102-1 through102-5). In some embodiments, a battery cell connector includes twosegments, three segments, or more segments. For example, first batterycell connector 100 includes five segments.

Each segment 102 defines a respective plane (e.g., lies in therespective plane). For example, as shown by axes 104, segments 102-1 and102-2 are parallel to an xz-plane; segments 102-3 and 102-4 are parallelto a xy-plane; segment 102-5 is parallel to a yz-plane. In someembodiments, a battery cell connector includes a plurality of segmentsthat define a plurality of respective planes (e.g., two or threeplanes). For example, first battery cell connector 100 includes fivesegments that define three planes (e.g., xy-plane, xz-plane, andyz-plane). In some embodiments, for example, as shown in first batterycell connector 100, the three planes are mutually substantiallyperpendicular.

Each segment has a respective longitudinal axis. For example, segments102-1 and 102-4 have respective longitudinal axes along the x-direction;segment 102-2 has a longitudinal axis along the z-direction; segments102-3 and 102-5 have respective longitudinal axes along the y-direction.In some embodiments, a segment's longitudinal axis is along a directionfrom a center of the segment to an adjacent bend or turn. In someembodiments, a segment's longitudinal axis is along a directionconnecting a bend or a turn on a first end of the segment and a bend ora turn on a second end of the segment, opposite the first.

First battery cell connector 100 includes a plurality of bends 106(e.g., bend 106-1; bend 106-2; and bend 106-3) coupling the plurality ofsegments together into a 3-D object (e.g., an object having substantialspatial extent and/or substantial rigidity in three orthogonaldirections). The plurality of bends coupling the plurality of segmentsinto a 3-D object comprises bends pointing in at least three differentdirections (e.g., having bending axes along three distinct directions).In some embodiments, the three different directions are orthogonal(perpendicular) directions. In some embodiments, at least two of theplurality of bends are not parallel to each other. In some embodiments,at least three of the plurality of bends are not parallel to each other.In some embodiments, two bends are not parallel to each other when theyhave respective bending axes that are not parallel to each other. Eachbend 106 is located between (e.g., couples) a unique pair of adjacentsegments of the plurality of segments. For example, bend 106-1 islocated between segment 102-1 and segment 102-5; bend 106-2 is locatedbetween segment 102-5 and segment 102-4; and bend 106-3 is locatedbetween segment 102-3 and segment 102-2. In this example, bend 106-1 hasan axis that is approximately in the z-direction; bend 106-2 has an axisthat is approximately in the y-direction; and bend 106-3 has an axisthat is approximately in the x-direction. As will be described below inconnection with FIGS. 26A-26C, the first battery cell connector 100 isformed from a two-dimensional U-shape metal sheet 2606 by bendingdifferent portions of the U-shape metal sheet 2606 into differentdirections at predefined locations. For example, both terminal segmentsare formed by bending the corresponding side portions of the U-shapemetal sheet 2606 into two opposite directions perpendicular to the planedefined by the U-shape metal sheet 2606 (see, e.g., 2626-2 and 2626-3 inFIG. 26C) and another bend 2626-1 is formed by bending the bottomportion of the U-shape metal sheet 2606. The unique pair of adjacentsegments on either side of a bend defines two distinct respectiveplanes. In some embodiments, the two distinctive planes areperpendicular to one another (e.g., the bend is a 90 degree bend). Insome embodiments, a bend has a radius of curvature. In some embodiment,a bend is bent along a respective bending axis that is parallel withboth of the two distinct respective planes (e.g., the bend ischaracterized by a bending axis). For example, the bending axis for bend106-1 is parallel to the z-axis. In some embodiments, the plurality ofbends 106 includes at least three bends having three distinct bendingaxes. In some embodiments, the three distinct bending axes areperpendicular to one another. In some embodiments, the plurality ofbends serves as vibration dampening elements (e.g., damp vibrationsalong directions perpendicular to the bend's respective bending axis).

In some embodiments, the battery cell connector is for use in a vehicle(e.g., an electrical car) and the bends are elastically deformable underpredefined operating conditions of the vehicle (e.g., vibration orshock). For example, in some embodiments, the bends act as springshaving a stiffness designed to dampen one or more resonance modes of thevehicle and/or the battery system.

In the example shown in FIG. 1, segment 102-1 is a first segment of theplurality of segments 102 that includes one or more first connectingelements 108 for a battery pole (e.g., an anode, a cathode, or aconnecting terminal or contact for an anode or a cathode) of a firstbattery cell. Segment 102-2 is a second segment of the plurality ofsegments 102 that includes one or more second connecting elements 110for a battery pole of a second battery cell. In some embodiments, thefirst connecting elements 108 include at least two connecting elements(e.g., first connecting elements 108-1 and 108-2) to provide rotationalstiffness for the connection to the first battery cell. In someembodiments, the second connecting elements include at least twoconnecting elements (e.g., second connecting elements 110-1 and 110-2)to provide rotational stiffness for the connection to the second batterycell. In some embodiments, a respective connecting element of the firstconnecting elements and the second connecting elements comprises anopening adapted to receive a battery terminal, wherein the batteryterminal is mechanically connected at least partially along acircumference of the opening (e.g., as shown in first battery cellconnector 100, each of the connecting elements 108/110 comprises anopening adapted to receive a battery terminal, which may comprise a boltscrewed into the battery). The one or more first connecting elements areelectrically coupled with the one or more second connecting elements. Insome embodiments, the plurality of segments comprise an electricalconductor forming the electrical coupling between the one or more firstconnecting elements 108 and the one or more second connecting elements110. In some embodiments, for example as shown in first battery cellconnector 100, the plurality of segments and the plurality of bends areformed by a single continuous metal sheet that comprises an electricalconductor forming the electrical coupling between the one or more firstconnecting elements 108 and the one or more second connecting elements110. In some embodiments, the connector 100 is made of copper oraluminum.

In some embodiments, the segments 102 that include connecting elements108/110 do not have a clearly discernible longitudinal axis. In someembodiments, the segments 102 that include connecting elements 108/110are respective segments in a plurality of segments that includes one ormore additional segments, each additional segment having a longitudinalaxis.

In some embodiments, first battery cell connector 100 includes one ormore (or a plurality of) turns 112 (for visual clarity, only a singleturn 112-1 is given a reference number in FIG. 1). Each turn 112 couplesa second unique pair of adjacent segments 102 in the plurality ofsegments 102. For example, turn 112-1 couples segment 102-3 and 102-4.The second unique pair of adjacent segments 102 have distinct respectivelongitudinal axes within the same respective plane. For example, segment102-3 has a longitudinal axis in the y-direction, segment 102-4 has alongitudinal axis in the x-direction, and both segment 102-3 and 102-4are parallel with the xy-plane. In some embodiments, the respective axesof segments coupled by a turn are perpendicular (e.g., the segments forman L-shape). In some embodiments, the plurality of segments has anL-shaped opening (e.g., at least a portion of the opening is L-shaped).

FIGS. 2-4 illustrate alternate views of first battery cell connector100, in accordance with some embodiments. FIG. 2 illustrates apartially-exploded-view of a first battery system 200 utilizing firstbattery cell connector 100. Battery system 200 includes a plurality of(e.g., two or more) battery cells (also called modules) 202 (e.g.,battery cell/module 202-1 and 202-2). First battery cell connector 100is coupled with battery cell/module 202-1 and 202-2 by bolts 204 runningthrough connecting elements 108/110 (FIG. 1), where the bolts serve asterminals of the battery cells. For example, in some embodiments, acathode of battery cell/module 202-1 is coupled with an anode of batterycell/module 202-2 so that battery cell/module 202-1 and batterycell/module 202-2 are electrically connected in series. FIG. 3illustrates an assembly view of the first battery system 200 utilizingthe first battery cell connector 100, in accordance with someembodiments. FIG. 4 illustrates a close-up of a portion 300 of theassembly view of the first battery system 200 utilizing the firstbattery cell connector 100, in accordance with some embodiments. Inparticular, FIG. 3 illustrates that first battery cell connector 100fits snuggly (e.g., securely) between battery cell/module 202-1 andbattery cell/module 202-2.

FIGS. 5-8 illustrate various views of a second battery cell connector500, in accordance with some embodiments. In particular, FIG. 5illustrates a perspective view of second battery cell connector 500;FIG. 6 illustrates a top view of second battery cell connector 500; FIG.7 illustrates a partially-exploded-view of second battery system 700utilizing second battery cell connector 500; and FIG. 8 illustrates aclose-up of a portion 800 of an assembly view of the second batterysystem 700 utilizing second battery cell connector 500. Second batterycell connector 500 is largely analogous to first battery cell connector100, but second battery cell connector 500 is arranged geometricallydifferently from first battery cell connector 100. Nevertheless, secondbattery cell connector 500 includes a plurality of segments 102 (e.g.,segments 102-6 through 102-10 and optionally others, not labeled forvisual clarity), a plurality of bends 106 (e.g., bends 106-4 andoptionally others, not labeled for visual clarity), connecting elements108/110, and a plurality of turns 112 (e.g., turn 112-2 and optionallyothers, not labeled for visual clarity). Segments 102, bends 106,connecting elements 108/110 and turns 112 have analogous features tothose described above with reference to FIGS. 1-4. As shown in FIGS.7-8, second battery cell connector 500 is used to connect batterycell/module 702-1 and battery cell/module 702-2.

FIGS. 9-12 illustrate various views of a third battery cell connector900, in accordance with some embodiments. In particular, FIG. 9illustrates a partially-exploded-view of a third battery system 950utilizing third battery cell connector 900; FIG. 10 illustrates anotherpartially-exploded-view of third battery system 950 utilizing thirdbattery cell connector 900; FIG. 11 illustrates an assembly view ofthird battery system 950 utilizing third battery cell connector 900; andFIG. 12 illustrates a close-up of a portion 1200 of the assembly view ofthird battery system 950 utilizing the third battery cell connector 900.Third battery cell connector 900 includes a plurality of segments 102; aplurality of bends 106 (e.g., bends 106-5 and 106-6), and connectingelements 108/110, which each have analogous features to those describedabove with reference to FIGS. 1-4. However, two respective segments 102(to wit, segment 102-11 and 102-12) of third battery cell connector 900are welded together (e.g., coupled together by a weld) to form a spring(e.g., a shock absorber or vibration dampener). In some embodiments, thespring forms a tweezer structure. In some embodiments, the tweezerstructure includes two planar segments having planes separated by asingle rotation (e.g., not a compound or multi-dimensional rotation) ofa few degrees (e.g., between 5-30 degrees). In some embodiments, eachlongitudinal axis of the respective segments 102 of third battery cellconnector 900 lie in a common plane. In some embodiments, third batterycell connector 900 does not include any turns. In some embodiments, thelongitudinal axes of each segment of third battery cell connector 900are co-planar. As shown in FIGS. 11-12, the welded segments of thirdbattery cell connector 900 are configured to be positioned betweenrespective battery/cells modules with the common plane of theirlongitudinal axes perpendicular to the plane of attachment to thebattery terminals.

FIGS. 13-17 illustrate various views of a fourth battery cell connector1300, in accordance with some embodiments. In particular, FIG. 13illustrates a perspective view of a fourth battery cell connector 1300;FIG. 14 illustrates a partially-exploded-view of fourth battery system1400 utilizing fourth battery cell connector 1300; FIG. 15 illustratesanother partially-exploded-view of fourth battery system 1400 utilizingfourth battery cell connector 1300; FIG. 16 illustrates an assembly viewof fourth battery system 1400 utilizing the fourth battery cellconnector 1300; and FIG. 17 illustrates a close-up of a portion 1406 ofthe assembly view of fourth battery system 1400 utilizing fourth batterycell connector 1300, in accordance with some embodiments. Fourth batterycell connector 1300 includes a plurality of segments 102 (e.g., segments102-13 through 102-18); a plurality of bends 106 (e.g., bends 106-7through 106-9), and connecting elements 108/110, as described above.Fourth battery cell connector 1300 electrically couples battery cellmodule 1402-1 and battery cell module 1402-2 of fourth battery system1400. Fourth battery cell connector 1300 is largely analogous to thirdbattery cell connector 900 (e.g., includes two welded segments thattogether form a spring/tweezer structure). However, the longitudinalaxes of each non-terminal segment of fourth battery cell connector 1300are parallel with the respective planes of the terminal segments ofbattery cell connector 1300. As shown in FIGS. 16-17, the weldedsegments of fourth battery cell connector 1300 are configured to bepositioned between respective battery/cells modules with theirlongitudinal axes lying in a plane parallel to the plane of attachmentto the battery terminals. The plurality of segments 102 of fourthbattery cell connector 1300 has an L-shaped opening 1302.

FIGS. 18-21 illustrate various views of a fifth battery cell connector1800, in accordance with some embodiments. In particular, FIG. 18illustrates a perspective view of fifth battery cell connector 1800;FIG. 19 illustrates a partially-exploded-view of a fifth battery system1900 utilizing fifth battery cell connector 1800; FIG. 20 illustrates anassembly view of fifth battery system 1900 utilizing fifth battery cellconnector 1800; and FIG. 21 illustrates a close-up of a portion 2000 ofthe assembly view of fifth battery system 1900 utilizing fifth batterycell connector 1800, in accordance with some embodiments. Fifth batterycell connector 1800 includes a plurality of segments 102 (e.g., segments102-19 through 102-26); a plurality of bends 106 (e.g., bends 106-10through 106-12), and connecting elements 108/110, as described above.Fifth battery cell connector 1800 electrically couples batterycell/module 1902-1 and battery cell/module 1902-2 of fifth batterysystem 1900. Fifth battery cell connector 1800 is largely analogous tothird battery cell connector 900 (e.g., includes two welded segmentsthat together form a spring/tweezer structure). As shown in FIGS. 20-21,the welded segments of fifth battery cell connector 1800 are configuredto be positioned adjacent to and outside of the respective battery/cellsmodules connect by fifth battery cell connector 1800. Moreover, thewelded segments of fifth battery cell connector 1800 have theirlongitudinal axes in a plane parallel to the plane of attachment to thebattery terminals.

FIGS. 22A-22B and FIG. 23 illustrate perspective views of additionalbattery cell connectors, in accordance with various embodiments. Thebattery cell connectors shown in FIGS. 22A-22B and FIG. 23 are largelyanalogous to the other battery cell connectors formed of a single metalsheet discussed above. However, the battery cell connectors shown inFIGS. 22A-22B and FIG. 23 illustrate the wide variety of arrangements ofbends, segments, and turns that are contemplated. For example, in FIG.22A, the battery cell connector has an elongated intermediate segment2204 between the first terminal segment 2202 and the second terminalsegment 2206. There are multiple bends and other intermediate segmentsconnecting each end of the elongated segment 2204 to one of the firstterminal segment 2202 and the second terminal segment 2206. FIG. 22Bdepicts a battery cell connector that is a slight variation of thebattery cell connector shown in FIG. 22A. In particular, the elongatedintermediate segment (2214-1, 2214-2) between the first terminal segment2212 and the second terminal segment 2216 has a bump 2218. This bump isformed by bending the elongated intermediate segment 2214 and separatesthe elongated intermediate segment into two sub-segments 2214-1 and2214-2. This bump 2218 serves as a spring that is elastically deformablealong the axis 2220 of the elongated intermediate segment 2214 to absorbthe vibration movement between the battery cells connected to the twoterminal segments 2220 and 2216. In some embodiments, the elongatedintermediate segment 2214 includes more than one bump; in some otherembodiments, the bump may be present in more than one segment includingboth intermediate segments and terminal segments.

As shown in FIGS. 24-25, in some embodiments, a battery cell connectoris provided that is formed of single continuous metal sheet. The batterycell connector includes a plurality of segments including a firstterminal segment that includes one or more first connecting elements fora battery pole of a first battery cell; a second terminal segment thatincludes one or more second connecting elements for a battery pole of asecond battery cell; and a plurality of additional segments connectingthe first terminal segment to the second terminal segment. Eachadditional segment defines a respective plane and having a respectivelongitudinal axis. The battery cell connector also includes a pluralityof bends coupling the plurality of segments together into a 3-D object,each bend located between a unique pair of adjacent segments of theplurality of segments. The unique pair of adjacent segments define twodistinct respective planes. The first terminal segment is not parallelto the second terminal segment and the one or more first connectingelements are electrically coupled with the one or more second connectingelements. For example, as shown in FIG. 24, the plurality of bendsincludes a first bend 2408 having a first bending axis 2410 and a secondbend 2412 having a second bending axis 2414 that is substantiallyperpendicular to the first bending axis. First terminal segment 2402 isnot parallel to second terminal segment 2404. In some embodiments, firstterminal segment 2402 is substantially perpendicular to second terminalsegment 2404. In some embodiments, the battery cell connector includes athird bend with a bending axis parallel to either the first bending axisor the second bending axis.

As shown in FIG. 25, in some embodiments, the battery cell connectorincludes only two bends. In some embodiments, the battery cell connectorfurther comprises a single turn that, together with the two bends, formsthe plurality of segments into the 3-D object. In FIG. 25, firstterminal segment 2502 is not parallel to second terminal segment 2504.

In some embodiments, at least two continuous sheets of metal, the atleast two continuous sheets of metal coupled together by the welding ofthe two respective segments forming the spring. In some embodiments, theplurality of bends point to at least three different directions. In someembodiments, the first and second segments of the plurality of segmentsare not parallel to each other.

Alternatively, in some embodiments, a battery cell connector is providedthat is formed of two or more continuous metal sheets. Battery cellconnector 900 (discussed above with reference to FIGS. 9-12), batterycell connector 1300 (discussed above with reference to FIGS. 13-17) andbattery cell connector 1800 (discussed above with reference to FIGS.18-21) are examples of such a battery cell connector. In someembodiments, the battery cell connector includes a plurality of segmentsof a metal conducting sheet, each segment defining a respective planeand having a respective longitudinal axis. The battery cell connectoralso includes a plurality of bends coupling the plurality of segmentstogether into a 3-D object, each bend located between a unique pair ofadjacent segments of the plurality of segments. The unique pair ofadjacent segments define two distinct respective planes. The batterycell connector includes at least one spring comprising two respectivesegments welded together (e.g., in a “tweezer” arrangement”). A firstsegment of the plurality of segments includes one or more firstconnecting elements for a battery pole of a first battery cell. A secondsegment of the plurality of segments includes one or more secondconnecting elements for a battery pole of a second battery cell. The oneor more first connecting elements are electrically coupled with the oneor more second connecting elements.

FIGS. 26A-26C illustrate a sheet metal process 2600 in accordance withsome embodiments. In some embodiments, any of the battery cellconnectors described herein (e.g., with reference to FIGS. 1-25) aremanufactured (e.g., formed), or partially manufactured (e.g., in thecase of a battery cell connector with “tweezers”), using sheet metalprocess 2600. For ease of explanation, sheet metal process is describedherein as producing a battery cell connector analogous to battery cellconnector 100, shown in FIG. 1.

The sheet metal process involves cutting (2602) a sheet of metal 2604into a two-dimensional (e.g., planar) U-shape 2606 comprising a firstplurality of planar segments 2608 (e.g., planar segments 2608-1 through2608-3) separated by a plurality of turns 2610 (e.g., turn 2610-1 and2610-2). For example, in some embodiments, the sheet of metal is a 1millimeter (mm) or 2 mm copper sheet. In some embodiments, cutting thesheet of metal into the two-dimensional shape comprises blanking thesheet of metal. In some embodiments, the two-dimensional shape issubstantially L-shaped or U-shaped. For example, two-dimensional shape2606 is substantially U-shaped.

In some embodiments, sheet metal process 2600 includes cutting (2612)(e.g., punching, sawing, milling, nibbling, or drilling) additionalfeatures into the two-dimensional shape 2606. For example, in someembodiments, sheet metal process 2600 includes cutting, in a firstsegment 2608-1 of the plurality of segments 2608, one or more firstconnecting elements 2614 for a battery pole of a first battery cell.Sheet metal process 2600 also includes cutting, in a second segment2608-3 of the plurality of segments, one or more second connectingelements 2616 for a battery pole of a second battery cell. In someembodiments, cutting the one or more first connecting elements andcutting the one or more second connecting elements comprises drilling orhole punching the one or more first connecting elements and the one ormore second connecting elements. In some embodiments, the additionalfeatures include L-shaped or U-shaped cutouts 2618.

Sheet metal process 2600 includes bending 2620 the two-dimensional shape2606 into a three-dimensional shape 2622 comprising a second pluralityof planar segments 2624 (for visual clarity, only some of planarsegments 2624 have been labeled in FIG. 26C). In some embodiments, thesecond plurality of planar segments 2624 having a greater number ofsegments than the first plurality of planar segments 2608 (e.g., theoperation of bending creates additional planar segments—that is, when aplanar segment is bent, in some circumstances, it creates two planarsegments coupled by a bend). The three-dimensional shape includes aplurality of bends 2626 separating respective segments of the secondplurality of planar segments and pointing to at least three differentdirections. In some embodiments, the three different directions aremutually orthogonal directions (e.g., the plurality of bends includesthree bends with three different bending axes that are all mutuallyorthogonal to the other bending axes). In some embodiments, afterbending, the first segment and the second segment are not parallel toeach other.

The foregoing description, for purposes of explanation, has beendescribed with reference to specific embodiments. However, theillustrative discussions above are not intended to be exhaustive or tolimit the invention to the precise forms disclosed. Many modificationsand variations are possible in view of the above teachings. Theembodiments were chosen and described in order to best explain theprinciples of the invention and its practical applications, to therebyenable others skilled in the art to best utilize the invention andvarious embodiments with various modifications as are suited to theparticular use contemplated.

It will be understood that, although the terms “first,” “second,” etc.may be used herein to describe various elements, these elements shouldnot be limited by these terms. These terms are only used to distinguishone element from another. For example, a first segment could be termed asecond segment, and, similarly, a second segment could be termed a firstsegment, without changing the meaning of the description, so long as alloccurrences of the “first segment” are renamed consistently and alloccurrences of the “second segment” are renamed consistently. The firstsegment and the second segment are both segments, but they are not thesame segment.

The terminology used herein is for the purpose of describing particularimplementations only and is not intended to be limiting of the claims.As used in the description of the implementations and the appendedclaims, the singular forms “a,” “an” and “the” are intended to includethe plural forms as well, unless the context clearly indicatesotherwise. It will also be understood that the term “and/or” as usedherein refers to and encompasses any and all possible combinations ofone or more of the associated listed items. It will be furtherunderstood that the terms “comprises” and/or “comprising,” when used inthis specification, specify the presence of stated features, integers,steps, operations, elements, and/or components, but do not preclude thepresence or addition of one or more other features, integers, steps,operations, elements, components, and/or groups thereof.

As used herein, the term “if” may be construed to mean “when” or “upon”or “in response to determining” or “in accordance with a determination”or “in response to detecting,” that a stated condition precedent istrue, depending on the context. Similarly, the phrase “if it isdetermined [that a stated condition precedent is true]” or “if [a statedcondition precedent is true]” or “when [a stated condition precedent istrue]” may be construed to mean “upon determining” or “upon adetermination that” or “in response to determining” or “in accordancewith a determination” or “upon detecting” or “in response to detecting”that the stated condition precedent is true, depending on the context.

What is claimed is:
 1. A battery cell connector, comprising: a pluralityof segments, comprising: a first terminal segment that includes one ormore first connecting elements for a battery pole of a first batterycell; a second terminal segment that includes one or more secondconnecting elements for a battery pole of a second battery cell; one ormore additional segments connecting the first terminal segment to thesecond terminal segment, each additional segment defining a respectiveplane and having a respective longitudinal axis; and a plurality ofbends coupling the plurality of segments together into a 3-D object,each bend located between a unique pair of adjacent segments of theplurality of segments, wherein the unique pair of adjacent segmentsdefine two distinct respective planes, wherein the first terminalsegment is not parallel to the second terminal segment and the one ormore first connecting elements are electrically coupled with the one ormore second connecting elements.
 2. The battery cell connector of claim1, further comprising a plurality of turns, each turn coupling a secondunique pair of adjacent segments in the plurality of segments, whereinthe second unique pair of adjacent segments have distinct respectivelongitudinal axis within the same respective plane.
 3. The battery cellconnector of claim 1, wherein the plurality of segments comprise anelectrical conductor forming the electrical coupling between the one ormore first connecting elements and the one or more second connectingelements.
 4. The battery cell connector of claim 1, wherein theplurality of segments has an L-shaped opening.
 5. The battery cellconnector of claim 1, wherein the plurality of bends comprise vibrationdampening elements.
 6. The battery cell connector of claim 1, whereinthe battery cell connector is for use in a vehicle and the plurality ofbends are elastically deformable within a set of operating conditions ofthe vehicle.
 7. The battery cell connector of claim 1, wherein theplurality of bends includes three bends.
 8. The battery cell connectorof claim 7, wherein the three bends have three distinct axes of bending.9. The battery cell connector of claim 8, wherein the three distinctaxes of bending are substantially perpendicular to one another.
 10. Thebattery cell connector of claim 1, wherein the plurality of segmentsincludes three segments.
 11. The battery cell connector of claim 10,wherein the three segments define three distinct respective planes. 12.The battery cell connector of claim 11, wherein the three distinctrespective planes are substantially perpendicular.
 13. The battery cellconnector of claim 1, wherein a respective connecting element of thefirst connecting elements and the second connecting elements comprisesan opening adapted to receive a battery terminal, wherein the batteryterminal is mechanically connected at least partially along acircumference of the opening.
 14. The battery cell connector of claim 1,further including at least one vibration-absorbent bump formed in arespective segment of the plurality of segments.
 15. The battery cellconnector of claim 1, wherein: the plurality of bends includes a firstbend having a first bending axis and a second bend having a secondbending axis that is substantially perpendicular to the first; and thefirst terminal segment and the second terminal segment are substantiallyperpendicular to each other.
 16. The battery cell connector of claim 15,wherein: the plurality of bends includes only two bends; and the batterycell connector further comprises a single turn that, together with thetwo bends, forms the plurality of segments into the 3-D object, whereinthe turn couples a second unique pair of adjacent segments in theplurality of segments, wherein the second unique pair of adjacentsegments have distinct respective longitudinal axis within the samerespective plane
 17. The battery cell connector of claim 15, wherein theplurality of bends includes a third bend having a third bending axisthat is substantially parallel to the first bending axis.